Wire Technology (eBook)

Process Engineering and Metallurgy

Roger N. Wright (Autor)

eBook Download: PDF | EPUB

2010 | 1. Auflage
332 Seiten
Elsevier Science (Verlag)
978-0-12-382093-8 (ISBN)

Infos

Wire drawing is a metalworking process used to reduce the diameter of a wire by pulling the wire through a single, or series of, drawing die(s). The engineering applications of wire drawing are broad and far-reaching, including electrical wiring, cables, tension-loaded structural components, springs, paper clips and spokes for wheels. This all-new, classical text is the first to explain the complex theory and sophisticated engineering concepts with relation to wire drawing in an accessible and universal way for practicing engineers. Designed to facilitate the entry and training of new engineers and upgrade the professional practice of those already in the field in the face of increased product demands and tightening specifications, this essential resource by industry expert Roger Wright provides: - A technical overview and introduction of engineering concepts related to wire drawing, suitable for beginners and practiced engineers looking to brush up on the theory behind the process - An interface with basic engineering education so as to provide an accessible introduction for engineers new to the field - Real-world worked examples, problems and protocols based on true life engineering scenarios and challenges - Unique coverage of the author's own pass design and risk prediction calculations, developed through decades of research and wire industry consulting Whilst most competing titles are less practical in their approach and focus on either ferrous, non-ferrous or electrical, our book takes a universal approach more suited to the practicing engineer who needs knowledge of wire drawing across the board. Ideal for use as a complete insight into the process from start to finish or a dip-in resource for practical problem-solving, this versatile work-a-day guide, training tool and desk reference will help readers train their staff and adapt and improve processes at minimal cost for maximum performance. - Provides a unique universal approach, covering ferrous and non-ferrous metals - Authored by an internationally-recognized specialist in wire drawing with extensive academic and industry experience - Real-world worked examples, problems and protocols based on true life engineering scenarios and challenges allow engineers to easily apply the theory to their workplace to improve processes, productivity and efficiency - Compact, concise and practical in comparison to the large, competing handbook tomes that are overwhelming for beginners and impractical for day-to-day work use - Ideal for use as a complete insight into the process from start to finish or as a dip-in resource for practical problem-solving, analysis and trouble-shooting

Roger N. Wright, Professor Emeritus, School of Engineering, Rensselaer Polytechnic Institute, has contributed broadly to the literature in the areas of metallurgy and metals processing, and is active as a short-course lecturer and consultant. Prior to joining Rensselaer, he was a senior staff member at Westinghouse Research Laboratories and at Allegheny Ludlum Steel Corporation. He holds B.S. and Sc.D. degrees in metallurgy from Massachusetts Institute of Technology. He is aregistered professional engineer and a fellow of ASM International and of the Society of Manufacturing Engineers.

Inhalt

Cover 1
Wire Technology 2
Dedication 6
Contents 8
Preface 14
About the Author 16
1. The General Idea 18
1.1. Concepts 18
1.2. How Does Drawing Work? 19
1.3. Questions and Problems 22
2. A Brief History of Technology 24
2.1. Ancient and Early Technology 24
2.2. The Nineteenth Century 26
2.3. The Twentieth Century 27
2.4. Further Reading 28
2.5. Questions and Problems 28
3. Twentieth Century Equipment Concepts 30
3.1. Overview 30
3.2. Benches 30
3.3. Blocks 31
3.4. Multiple-die Machines 32
3.5. Other in-line Processes 34
3.6. Questions and Problems 34
4. Basic Engineering Variables Pertinent to Drawing 36
4.1. General Quantities 36
4.2. Quantities Describing the Workpiece and Die During Drawing 40
4.3. Questions and Pro 43
5. Basic Drawing Mechanics 46
5.1. A Simple Drawing Stress Model 46
5.2. Drawing Limits 50
5.3. An Illustrative Calculation 51
5.4. The Issue of Optimum Die Angles and ? Values 51
5.5. Die Pressure 52
5.6. Centerline Tension 54
5.7. Plastic Flow Outside the Drawing Cone 55
5.8. Effects of Back Tension 57
5.9. Questions and Problems 58
6. Drawing Temperature 60
6.1. Contributions to the Drawing Temperature 60
6.2. Temperature Measurement 66
6.3. Interpass Cooling 67
6.4. Practical Examples of Drawing Temperature Effects 67
6.5. Questions and Problems 73
7. Drawing Speed 74
7.1. Definition and Basic Formulas 74
7.2. The Role of Drawing Speed in Analysis 75
7.3. The Effect of Drawing Speed on Lubrication 77
7.4. Some Practical Issues 78
7.5. Questions and Problems 79
8. Friction, Lubrication, and Surface Quality 82
8.1. Modes of Lubrication and Related Friction Response 82
8.2. Physical Conditions in the Lubricant Layer 88
8.3. Quantifying the Friction Stress 91
8.4. Drawing With High Friction 92
8.5. Redraw Stock Surface Conditioning Issues 92
8.6. Characterization With Microscopy 93
8.7. Illustrations of Microscopic Characterization and Analysis 94
8.8. The Development of Chevrons (Crow’s Feet) 99
8.9. Questions and Problems 105
9. Drawing Die and Pass Schedule Design 106
9.1. General Aspects and The Role Of ? 107
9.2. Common Die Materials 111
9.3. Other Elements of Die Design 116
9.4. Pressure Dies 118
9.5. Die Wear and Die Life 119
9.6. Pass Schedule Concepts 121
9.7. Drawing Practice and Cast and Pitch Control 126
9.8. Questions and Problems 127
10. Shaped Dies and Roller Dies 130
10.1. Drawing Shapes with One-Piece Dies 130
10.2. Drawing with Unpowered Roller Die Systems 135
10.3. “Drawing” with Powered Roller Die Systems 138
10.4. Roll Gap Issues 140
10.5. Questions and Problems 141
11. Mechanical Properties of Wire and Related Testing 144
11.1. The Flow Stress of the Wire 145
11.2. The Tensile Test 147
11.3. The Crystal Plasticity Basis for the Flow Curve 155
11.4. Other Mechanical Tests 161
11.5. Hardness Tests 161
11.6. Compression Tests 162
11.7. Bending Tests 165
11.8. Torsion Tests 166
11.9. Creep Testing 168
11.10. Fatigue Testing 170
11.11. Springback Testing 170
11.12. Questions and Problems 171
12. Drawability and Breaks 174
12.1. Practical Definitions 174
12.2. Measuring and Estimating Drawability 175
12.3. Categorizing Drawing Breaks 181
12.4. Mechanics of Drawing Breaks 184
12.5. The Generation of “Fines” 188
12.6. Questions and Problems 190
13. Relevant Aspects of Copper and Copper Alloy Metallurgy 192
13.1. Important Properties of Copper 193
13.2. Primary Processing 193
13.3. Crystal Structure, Grains, Texture, Anisotropy, and Springback 197
13.4. Flow Stress, Cold Working, and Annealing 199
13.5. Solid Solutions and Phase 202
13.6. Factors Affecting Conductivity/Resistivity 204
13.7. Dilute Copper Alloys 205
13.8. High Alloy Systems 209
13.9. Beryllium Copper, A Precipitation Strengthening (Hardening) Alloy 212
13.10. Questions and Problems 214
14. Relevant Aspects of Carbon and Low Alloy Steel Metallurgy 216
14.1. Important Properties of Steel 217
14.2. Primary Processing 217
14.3. The Iron-Iron Carbide Phase Diagram 221
14.4. Austenite Decomposition 224
14.5. Structure-Mechanical Property Relations 226
14.6. Transformation Diagrams 227
14.7. Flow Stress, Cold Working, and Annealing 232
14.8. Aging in Steel 234
14.9. Carbon Steel Compositions 242
14.10. Low Alloy Steel Compositions 243
14.11. Questions and Problems 244
15. Other Metallurgical Systems for Wire Technology 246
15.1. Aluminum and its alloys 246
15.2. Austenitic Stainless Steels 251
15.3. Tool Steels 254
15.4. Nickel and Nickel Alloys 257
15.5. Questions and Problems 259
16. Wire Coatings 262
16.1. Reasons for Coating Wire 262
16.2. Coating Types and Coating Processes 262
16.3. Enamels and Enameling 263
16.4. Extrusion 264
16.5. Hot Dipping 266
16.6. Electro-Coating 266
16.7. Other Coating Technologies 268
16.8. Zinc Alloy Coating of Steel – A Detailed Illustration and Analysis 268
16.9. Composite Mechanical Properties of Coated Wire 270
16.10. Questions and Problems 273
17. Redraw Rod Production 274
17.1. The Rod Rolling Process 274
17.2. The Oval/Round Sequence 276
17.3. Other Geometrical Sequences 280
17.4. Some Process Correction Contexts 281
17.5. Questions and Problems 282
18. Wire Forming 284
18.1. Scope 284
18.2. Bending 284
18.3. Twisting 286
18.4. Stretching 288
18.5. Upsetting 288
18.6. Swaging 289
18.7. Cold Extrusion 293
18.8. Questions and Problems 295
19. Physical Properties 296
19.1. Scope 296
19.2. Density 296
19.3. Melting Points and Ranges 297
19.4. Specific Heat 298
19.5. Thermal Conductivity 298
19.6. Electrical Resistivity 299
20. Current and Near-Term Developments 302
20.1. Scope 302
20.2. Drawing Machines 303
20.3. Long-Life Dies For Ferrous Drawing 305
20.4. Measurement and Instrumentation 306
20.5. Annealing 308
20.6. Payoff and Take-Up Systems 309
List of Symbols 314
References 320
Selected Formulas 326
Index 328

Produkt-Details

• Erscheint lt. Verlag: 3.12.2010
• Sprache: englisch
• Themenwelt: Technik ► Bauwesen
• Themenwelt: Technik ► Maschinenbau
• Themenwelt: Wirtschaft ► Betriebswirtschaft / Management ► Logistik / Produktion
• ISBN-10: 0-12-382093-6 / 0123820936
• ISBN-13: 978-0-12-382093-8 / 9780123820938